Soft tip cannula

ABSTRACT

The present disclosure describes numerous example medical instruments that include an elongated portion having a proximal end and a distal end, and a passage defined therethrough and a soft tip coupled to the distal end of the elongated portion. The tip may be formed from a soft material. In some instances, the soft material may have a hardness less than the material forming the elongated portion. The tip may also include a passage that may be of a substantially equivalent size as the passage of the elongated portion. The tip may be coupled to the distal end of the elongated portion at an engagement site having a surface area greater than a cross-sectional area of the elongated portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of application Ser. No. 13/619,369, filed Sep. 14, 2012, which claims the benefit of provisional Application No. 61/672,550, filed Jul. 17, 2012, the entire contents of each being incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates generally to medical instruments. In particular, the disclosure relates to a cannula having a soft tip for ophthalmic procedures.

BACKGROUND

Cannulas are used in ophthalmic surgical procedures, such as retinal detachment surgery, to aspirate materials such as fluids including blood, aqueous humor, and infused balanced saline solutions. For ophthalmic surgical procedures, it is important that the instrument tip be designed to prevent or avoid damage to the eye tissue in the event of physical contact with the eye.

SUMMARY

According to one aspect, the disclosure relates to a medical instrument including an elongated portion having a distal end and a first passage and a tip coupled to the distal end of the elongated portion at an engagement site. The tip may include a second passage substantially equivalent in size to the first passage of the elongated portion. The engagement site may have a surface area greater than a cross-sectional area of the elongated portion.

Another aspect is directed to a method of forming a medical instrument including preparing a distal end of an elongated portion for attachment of a soft tip. Preparing the distal end may include laser cutting, water jet cutting, milling, drilling, a combination thereof, or any other suitable manufacturing method. The method may also include attaching a tip to the distal end of elongated portion. Attaching the tip may include molding, injection molding, insert molding, extrusion, adhering, a combination thereof, or any other suitable joining technique.

The various aspects may include one or more of the following features. The engagement site may include a tongue and groove connection. The tongue and groove connection may include at least one tongue formed on one of the elongated portion or the tip and at least one groove formed on the other of the elongated portion or the tip. The at least one tongue and the at least one groove may be interlocked with each other. The engagement site may include an enhanced surface. The tip may be molded to the enhanced surface. The elongated portion may include a needle or a cannula. The elongated portion may have a gauge size of 25 or less (e.g., 26 gauge, 27 gauge, or smaller gauge size). The passage of the tip may be tapered. The passage of the tip may taper from a smaller cross-sectional opening at a proximal end of the tip to a larger cross-sectional opening at a distal end of the tip. A distal end of the tip may be outwardly flared.

The tip may be formed from an elastomeric material. At least a portion of the tip may be formed from silicone, polyurethane, polyethylene, polypropylene, polystyrene, polytetrafluoroethylene, fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), polyether ether ketone (PEEK), polyetherimide (PEI), polyamide imide (PAI), thermoplastic polyimides (TPI), polybenzimidazol (PBI), rubber, latex, combinations thereof, or other polymer or plastic compounds.

The details of one or more implementations of the present disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1D show views of an example instrument having a soft tip.

FIG. 2 is a detail view of an example instrument showing a shape of an example groove formed in the instrument.

FIG. 3 shows a detail view of an engagement site of an example instrument.

FIG. 4 is an example cross-sectional view of the instrument shown in FIG. 3.

FIG. 5 is a cross-sectional view of another example instrument.

FIG. 6 is a cross-sectional view of another example instrument having a soft tip.

FIG. 7A is a side view of a further example instrument having a soft tip.

FIG. 7B is a detail view of an end of the cannula of FIG. 3A shows an engagement site between the soft tip and an elongated portion of the instrument.

FIG. 8 is a partial detail view of another example instrument in an exploded configuration.

FIG. 9 is a detail view of the interface of the soft tip and the elongated portion of an example instrument illustrating partial separation of the soft tip from the elongated portion.

FIG. 10 is a graphical illustration of passive flow characteristics of different sized instruments with and without a soft tip.

FIG. 11 shows a distal end of a soft tip cannula.

Those skilled in the art will appreciate and understand that the various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the features shown therein.

DETAILED DESCRIPTION

The present disclosure is directed to an instrument having soft tip and an interface formed between the soft tip and an elongated portion of the instrument. In some instances, the elongated portion may be a cannula. In some instances, the instruments may be used in procedures such as ophthalmic surgical procedures. However, the disclosure is not so limited, and the elongated portion and the interface formed therebetween may be utilized in any suitable or desired environment or purpose.

FIG. 1 shows an example instrument 10 having a soft tip 130. The instrument 10 includes an elongated portion 100 an outer surface 107, having a proximal end 101 and a distal end 105 and defining a passage 115. The passage 115 defines a wall 113 that is formed between the passage 115 and the outer surface 107. In some implementations, the elongated portion 100 may be a needle or a cannula. In other implementations, the elongated portion 100 may correspond to other types of hollow bodies for use in other types of procedures. Thus, although the balance of the description is made with reference to ophthalmic surgical procedures, the scope of the disclosure is not so limited and may be utilized in many other applications, both medical and non-medical.

The elongated portion 100 may be formed from any desired or suitable material. For example, in some instances, the elongated portion 100 may be formed from a metal such as stainless steel or titanium. However, the elongated instrument body 100 may be formed from any suitable material. For example, the elongated portion 100 may be formed from a biocompatible material, including a biocompatible polymer, metal, ceramic, or other material. In other implementations, the instrument body may be formed from silicone, polyurethane, polyethylene, polypropylene, polystyrene, polytetrafluoroethylene, fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), polyether ether ketone (PEEK), polyetherimide (PEI), polyamide imide (PAI), thermoplastic polyimides (TPI), polybenzimidazol (PBI), rubber, latex, or other medically compatible metals, polymers, or plastic compounds.

The passage 115 may be utilized to conduct an aspiration or irrigation fluid flow. The instrument 10 also includes a soft tip 130. The soft tip 130 may be coupled at a distal end 131 of the elongated portion 100. The soft tip 130 may include an end surface 133 and may define a passage 134. Also, in some instances, a cross-sectional size of the passage 134 may be the same as a cross-sectional size of the passage 115. For example, for passages 115 and 134 having cylindrical shapes, the diameters of the passages 115 and 134 may be the same or substantially the same. In other implementations, the size and/or cross-sectional shape of the passages 115 and 134 may be different. Additionally, the passage 115 and 134 may be aligned with each other. For example, a longitudinal axis of the passages 115 and 134 may be aligned. The passages 115 and 134 define a continuous passage 170 extending through the instrument 10.

The soft tip 130 is adapted to provide a cushioning and/or non-abrasive engagement with delicate tissues or membranes, such as in a patient's eye. In some instances, the soft tip 130 may be formed from any soft material. Particularly, in some instances, the soft tip 130 may be formed from any medically compatible soft material. The soft tip 130 may be formed from materials including, for example, silicone, polyurethane, polyethylene, polypropylene, polystyrene, polytetrafluoroethylene, fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), polyether ether ketone (PEEK), polyetherimide (PEI), polyamide imide (PAI), thermoplastic polyimides (TPI), polybenzimidazol (PBI), rubber, latex, combinations thereof, or other medically compatible polymers or plastic compounds. In some instances, the material forming the soft tip 130 may have a durometer value of 80 A. In other instances, the material forming the soft tip 130 may have a durometer value within the range of 50 A to 50 D. However, the disclosure is not so limiting. Rather, these hardness values are provided merely as examples. Thus, the material forming the soft tip 130 may have any desired hardness. In some implementations, the elongated portion and soft tip may comprise the same or similar materials.

In some instances, the elongated portion 100 may have a length within the range of approximately 20.0 mm to 40.0 mm. In other implementations, the elongated portion 100 may have a longer or shorter length. Further, the elongated portion 100 may have a gauge size between 20 and 30 gauge. Thus, for example, in some instance, the elongated portion 100 may have an outer diameter within the range of 0.30 mm to 0.40 mm. However, the scope of the disclosure is not so limited. Thus, in other implementations, the elongated portion 100 may be of any suitable or desired size. Additionally, in some instances, the passages 115 and 134 may a diameter within the range of approximately 0.30 mm to 0.01 mm. The soft tip 130 may have a length within the range of about 0.5 mm to 1.0 mm. Further, an exterior size and shape of the soft tip 130 may correspond to the size and shape of the elongated portion 100, thereby producing a smooth transition between the elongated portion 100 and the soft tip 130. For example, for an instrument 10 having a cylindrical shape, outer diameters of the elongated portion 100 and the soft tip 130 may be the same. Also, the diameters of the passages 115 and 134 may also be the same providing a continuous passage through the instrument 10.

In other implementations, the size and shapes of the elongated portion 100 and soft tip 130 may be different. For example, in some instances, the outer diameter of the elongated portion 100 may be different from the outer diameter of the soft tip 130. Thus, in some instances, a step or transition may exist at the interface between the soft tip 130 and the elongated portion 100. Further, in some instances, the soft tip 130 may have a tapered exterior surface. Thus, in some instances, the instrument 10 may include a smooth transition between the elongated portion 100 and the soft tip 130 while the soft tip 130 may taper to a smaller size at a distal end 132 thereof. Also, in some instances, the diameters of the passages 115 and 134 may be different such that there is a step or transition between the passage 115 and passage 134.

The soft tip 130 and the elongated portion 100 may include interlocking features 119, e.g., one or more interlocking tongues 120 and grooves 121. In some implementations, as shown in FIGS. 1A and 1B, the elongated portion 100 may define one or more grooves 121 formed at a distal end 105 of the elongated portion 100. Also, the soft tip 130 may define one or more tongues 120 at a proximal end 131 of the soft tip 130. The tongues 120 are received into the grooves 121 to interlockingly secure the soft tip 130 to the elongated portion 100. An engagement site 150 defines a location where the soft tip 130 and the elongated portion 100 are coupled together. The engagement site 150 may define a surface area 151 greater than a cross-sectional area of the elongated portion 100 so as to facilitate a secure and stable connection between the soft tip 130 and the elongated portion 100, even for small gauge sizes (e.g., 25 gauge or less). Further, the interlocking features provides for coupling the soft tip 130 to the elongated portion 100 while avoiding an undesirable reduction in flow rates through the passages 115, 134.

As shown in FIG. 1A, the soft tip 130 may be coupled at a circumferential edge 106 of the distal end 105 of the elongated portion 100 at the engagement site 150. As FIGS. 1B-1D illustrate, the engagement site 150 may have interlocking features 119 adapted to increase the surface area 151 at the engagement site 150 where the soft tip 130 engages the distal end 105 of the elongated portion 100. As explained above, in some instances, the surface features 119 may include one or more interlocking tongue 120 and groove 121. As illustrated in FIG. 1A, in some instances, the one or more tongues 120 of the soft tip 130 may engage and interlock with corresponding grooves 121 formed in the circumferential edge 106 of the distal end 105 of the elongated portion 100. In other instances, the elongated portion 100 may include tongues that are received in grooves formed in the soft tip 130.

The soft tip 130 and the elongated portion 100 may be coupled together utilizing numerous manufacturing methods. For example, coupling of the soft tip 130 with the elongated portion 100 may be accomplished with extrusion, casting, molding, injection molding, insert molding, welding, adhesives, or other desired or suitable methods. For example, the soft tip 130 may be formed onto the elongated portion 100 by insert molding. Moreover, the coupling may be accomplished using combinations of one or more of these methods.

FIGS. 1B-1C illustrate the distal ends 105 of example implementations of the elongated portion 100. However, as explained above, the interlocking features 119 shown in FIGS. 1B-1C may alternately be formed in the soft tip 130. As shown in FIGS. 1B-1C, the elongated portion 100 may include a plurality of grooves 200. For example, as illustrated, the elongated portion 100 may include two grooves 200. However, in other instances, any number of grooves 200 may be used. Further, the grooves 200 may be identical in shape to each other. However, in other instances, the shapes of the grooves 200 may be different from each other. In some instances, the grooves 200 may be radially offset from each other. For example, the grooves 200 may be arranged at a 180° offset about a longitudinal axis of the elongated portion 100 along the circumferential edge 106. In other instances, the grooves 200 may be arranged at different radial offsets. Moreover, elongated portions 100 or soft tips 130 having more than two grooves 200 may be offset from each other at regular intervals. In other instances, the grooves 200 may be offset from each other at irregular intervals.

The grooves may be formed in a variety of shapes or configurations. For example, as shown in FIG. 1A, the interlocking features 119 may include grooves 121 having a generally circular shape. Alternately, as shown in FIGS. 1B and 1C, the interlocking features 119 may include grooves 200 having a flattened circular or oval shape. Although, in other instances, the grooves 200 may have any desired shape. Still further, as shown in FIG. 1D, the interlocking features 119 may have a combination of deep grooves 200 and shallow grooves 202. The grooves 202 may be radially offset 180° from each other. In some instances, the shallow grooves 202 may be in the form of arc-shaped recesses and may be radially offset 180° from each other. Further, the set of grooves 200 may be radially offset from the set of grooves 202 by 90°. Also, the deeper grooves 200 may be generally circular or oval in shape. Thus, grooves of varying depths may be utilized. However, this configuration is used merely as an example. Any number of grooves having any number of different shapes and configurations may be used. With the grooves of one configuration or another, distal end 105 of the elongated portion 100 (or, in the case of the proximal end 131 of the soft tip 130) may have the appearance of a “jigsaw puzzle piece.” Additionally, the grooves enlarge the surface area 151 of the circumferential edge 106 to provide for enhanced contact between the soft tip 130 and the elongated portion 100. FIG. 2 shows a further example of a groove 121 that may be formed. FIG. 2 shows the grooves 121 as having a generally flattened end.

FIG. 3 shows a detail view of the engagement site 150 of an example instrument 10 according to some implementations. In the example shown, the interlocking tongues 120 and grooves 121 have an enlarged portion 208 and a reduced portion 210. FIG. 4 shows a cross-sectional view of the example instrument taken along line A-A through the reduced portion 210. Referring to FIG. 4, the example instrument 10 includes six pairs of corresponding tongues 120 and grooves 121. However, this is provided merely as an example. Thus, any number of tongues 120 and grooves 121 may be provided. As shown, in some instances, the material forming the tongues 120 may also form an annular portion 172 that overlaps a portion of the passage 170 at the engagement site 150. The annular portion 172 may reduce a cross-sectional area of the passage 170 through at least a portion of the engagement site 150. In other implementations, though, the engagement site 150 may not include an annular portion 172 within the passage 170. For example, FIG. 5 shows an example instrument 10 that does not include the annular portion 172.

Referring again to FIG. 4, the illustrated example instrument 10 may have an outer diameter 174 and an inner diameter 176. The annular portion 172 may define a diameter 178. In the case of a 27 gauge cannula, the outer diameter 174 may be 0.40 mm and the inner diameter 176 may be 0.30 mm. The diameter 178 may be within the range of 0.30 mm to 0.27 mm. Thus, in some instances, a thickness of the annular portion 172 may be within the range of 0.0 mm to 0.015 mm.

Further, the reduced portion 210 may have a thickness 180. The thickness 180 may be within the range 0.05 mm to 0.10 mm. Thus, in some instances, the ratio of the area defined by the reduced portions 210 to the entire cross-sectional area of the instrument 10 (not including the annular portion 172) may be between 14 and 27 percent. However, the particular values described above are provided merely as examples. Thus, in other instances, the thickness 180 may be any desired value. Further, although six sets of tongues 120 and grooves 121 are shown, more or fewer may be included. Also, in other instances, the ratio may be higher or smaller than the range indicated. Still further, the thickness of the annular portion 172 may be greater or smaller than the examples described above. That is, the values provided are for example purposes only and are not intended to be limiting.

Although shown as a circular cross-section, as explained herein, the scope of the disclosure is not so limited. Thus, while the examples shown in FIGS. 3 and 4 have generally circular cross-sections, the cross-sections may have any desired shape. Further, the annular portion 172 may conform to the cross-sectional shape of the instrument such that the diameter 178 also substantially corresponds to the cross-sectional shape of the instrument 10 or may be defined to be any other shape. Thus, in some instances where the instrument 10 has a non-circular cross-sectional shape, the diameter 178 may still be defined to be circular. However, in still other instances, the diameter 178 may be defined to be any desired shape.

The various types of grooves or tongues may be formed in or about the distal end of the elongated portion 100 in any desired manner. For example, the grooves and/or tongues may be formed by laser cutting, water jet cutting, milling, drilling, electron discharge machining, chemical etching, electrolytic etching, or any other suitable method. The interlocking features 119 are designed to increase and/or enhance the cross-sectional surface area, e.g., surface area 151, at the engagement site 150 to facilitate attachment of the soft tip 130 to the elongated portion 100.

FIG. 6 shows an instrument 10′ according to an alternative implementation. The instrument 10′ includes an elongated portion 100 having a proximal end 101 and a distal end 105 and defining a flow passage 115 therethrough. The soft tip 130 includes a passage 134. The passages 115 and 130 may be similar to those explained above. The distal end 105 of the elongated portion 100 includes an enhanced surface 135 to enhance coupling of the soft tip 130 and the elongated portion 100. In some instances, the enhanced surface 135 may contain a network of pores or voids that are adapted to receive material forming the soft tip 130, thereby enhancing bond between the soft tip 130 and the elongate portion 100. In other instances, the enhanced surface 135 may be a roughened surface to increase a surface area to enhance bonding between the soft tip 130 and the elongated portion 100. In some implementations, the enhanced surface 135 may be formed with the use of urea. Further, in some instances, the enhanced surface 135 may be both porous and roughened. In still other implementations, the enhanced surface 135 may include other features, either alone or in combination with one or more of the features described herein to enhance bonding.

The distal end 105 of the elongated portion 100 may also be treated to enhance adhesion of the material forming the soft tip 130. For example, a plasma treatment may be applied to the distal end 105. The plasma treatment may clean, etch, and alter the chemistry of the material forming the elongated portion 100 to promote coupling of the soft tip 130 thereto. Further, a silicate layer may be formed at the distal end 105 of the elongated portion 100 to enhance adhesion of the soft tip 130 to the elongated portion 100.

The soft tip 130 may be molded, extruded onto, or adhered to the enhanced surface 135. The enhanced surface 135 may include one or more of pores, passages, or a texture that defines additional surface area at the engagement site 150 for interaction with the soft tip 130. Similarly, the soft tip 130 may include a surface that engages the enhanced surface 135 to form a bond between the soft tip 130 and elongated portion 100. The additional or enhanced surface area provided by the enhanced surface 135 facilitates the engagement between and adherence of the soft tip 130 to the elongated portion 100. In some instances, adherence between the soft tip 130 and the elongated portion 100 may be obtained by application of an adhesive that can flow into the surface features of the enhanced surface 135 and the corresponding surface of the soft tip 130 to enhance the adhesion therebtween. Alternatively, the soft tip 130 may be extruded or molded directly onto the enhanced surface 135 of the elongated portion 100, such as, for example, by insert molding. The material forming the soft tip 130, such as a plastic or elastomeric material, is then able to flow into the surface features (e.g., pores, cracks and/or passages) of the enhanced surface 135.

FIGS. 7A-7B illustrate another example instrument 10″. The soft tip 130 of instrument 10″ is connected at the distal end 105 of the elongated portion 100 via interlocking features 119 in combination with a enhanced surface 135 similar to the enhanced surface 135 described above. The enhanced surface 135 may be formed along an interior surface of one or more of the grooves 121. Alternately or in addition, one or more locations of the enhanced surface 135 may be provided along the circumferential edge 106. In other implementations, the enhanced surface 135 may be provided along the entire circumferential edge 106. As shown, the instrument 10″ includes six grooves 121, but any number of grooves 121 may be used. Thus, the soft tip 130 may be coupled to the elongated portion 100 via both interlocking provided by the mating tongues 120 and grooves 121 as well as the increased surface area provided by the enhanced surface 135. Again, while the grooves 121 are shown as being formed in the elongated portion 100, the grooves 121 may be formed in the soft tip 130 while the tongues 120 may be formed in the elongated portion 100.

FIG. 8 illustrates another example instrument 10″′. The instrument 10″′ includes a soft tip 130 having a circumferential edge 133 that is outwardly flared at distal end 132. In some instances, the soft tip 130 may be tapered all or a portion of its length from the flared circumferential edge 133 to a reduced cross-sectional size. For example, in some instances, the soft tip 130 may taper from an outer profile corresponding to that of the elongated portion 100 to an enlarged circumferential edge 133. Further, in some instances, the passage 134 may be tapered.

FIG. 8 also shows the distal end 105 of the elongated portion 100, with tongues 120 formed in the elongated portion 100 rather than the soft tip 130. The soft tip 130 may include one or more corresponding grooves 121 that are adapted to receive in the tongues 120 formed in the elongated portion 100. In some implementations, the grooves 121 may have an enlarged head 137. Similarly, the tongues 120 may have a shape complementary to the shape of the grooves 121 such that the tongues 120 are matingly received into the grooves 121. The grooves 121 and tongues 120 provide for an interlocking engagement. Further, the enlarged head 137 of the grooves 121 provides an enlarged perimeter and, hence, contact area at which the soft tip 130 and the elongated portion 100 engage each other. Consequently, the interlocking tongues 120 and grooves 121 provide for an improved connection between the soft tip 130 and the elongated portion 100 of the instrument 10″′.

FIG. 9 is a detail view of an example instrument 10 in which two of the grooves 121 and corresponding tongues 120 are shown. The soft tip 130 may be formed from silicone or other material. For example, the soft tip 130 may be formed from one or more of the materials identified above. Further, the soft tip 130 may be molded directly onto the elongated portion 100.

In one or more of the examples described herein, the grooves 120 formed in the distal end 105 of the elongated portion 100 may be formed by laser cutting. Similarly, for implementations in which the tongues 120 are formed at the distal end 105 of the elongated portion 100, the tongues 120 may be formed via laser cutting. However, other manufacturing methods may be utilized to form the tongues 120 or grooves 121 in the elongated portion 100. For example, other machining methods may be used. Thus, any suitable manufacturing operation may be used to form the grooves 121 or tongues 120.

In some instances, when coupling the soft tip 130 to the elongated portion 100, the instrument body may be placed in an injection mold defining a cavity adapted to form the soft tip 130. A portion of the elongated portion 100, such as the distal end 105, may extend into the cavity. Silicon or other suitable or desired material may be injected into the cavity forming the soft tip 130. The injected material flows into the grooves 121 formed in the distal end 105 of the elongated portion 100 or, alternately, around the tongues 120 formed at the distal end 105 to form the corresponding interlocking features. Further, the injected materials also fills in surface features of the elongated portion 100, such as the surface features of the perimeter defined at the distal end 105 by the grooves 121 or tongues 120 to further enhance the mechanical bond formed between the elongated portion 100 and the soft tip 130.

FIG. 9 shows the soft tip 130 partially separated from the elongated portion 100. For example, FIG. 9 may illustrate a condition in which the soft tip 130 has been partially torn away from the elongated portion 100. In some instances, separation of the soft tip 130 from the elongated portion 100 may result in the interlocking feature of the soft tip 130 remaining with the elongated portion 100. For example, as shown in FIG. 9, upon partial or complete separation of the soft tip 130 from the elongated portion, the tongues 120 formed at a proximal end 131 of the soft tip 130 may remain within the corresponding groove 121 and, hence, coupled to the elongated portion 100. Moreover, because the tongues 120 remain retained within the corresponding groove 121, the instrument 10 is less likely to become occluded by debris from the soft tip 130. That is, if the soft tip 130 were to become partially or completely separated from the elongated portion 100, the interlocking relationship between the tongues 120 and grooves 121 work to retain the tongues 120 of the soft tip 130, thereby preventing occlusion of the instrument 10 by the separated tongues 120. As a result, risk to a patient is reduced.

A further benefit is that the passage 134 may be the same size as the passage 115 formed in the elongated portion. This improves the flow capacity passing through the instruments as well as reducing the risk of occlusion within the soft tip 130. Further, the engagement of the soft tip 130 and the elongated portion 100 includes a surface area defined by the profile of the grooves 121 and tongues 120 that exceeds a surface area associated with a transverse cross-sectional area. Thus, the interlocking features of soft tip 130 and elongated portion 100 provide both mechanical interlocking and an increase in the surface area available for coupling while providing a lumen through the instrument having a continuous cross-sectional shape. Adhesives may also be used to augment coupling between the soft tip 130 and elongated portion 100 interlocking connection. Still further, in some implementations, the soft tip 130 and passage 134 formed therethrough may be tapered and a distal end 132 of the soft tip 130 may be flared to improve fluid flow characteristics through the instrument.

FIG. 10 illustrates passive flow characteristics through cannulas of a defined size. FIG. 10 also illustrates the passive flow characteristics of cannulas having a blunt tip as well as cannulas having a soft tip. Particularly, FIG. 10 displays measured passive flow data of cannulas having various diameters (e.g., 20 to 27 gauge). The passive flow data (in cm³/min.) represented in FIG. 10 were collected from experiments performed at a pressure of 66 mm of Hg (i.e., 1.28 psi or 0.88 bar). The passive flow data graphically illustrated in FIG. 10 are shown below in Table 1.

Table 1 includes flow rate data for passive flow through cannulas of the indicated types. For each indicated gauge size, Table 1 includes flow data of both a blunt tip cannula (i.e., a cannula that lacks a soft tip) and a cannula including a soft tip. For the 20, 23, 25, and 27 gauge cannulas identified with a single asterisk (*), a soft tip 700 is received into passage 710 of cannula 720, as shown in FIG. 11.

The last entry in Table 1 identified with two asterisks (**) includes data for both a blunt tip cannula and a soft tip cannula. The soft tip cannula is coupled to the cannula as described herein. Particularly, the soft tip is coupled to an end of the cannula via insert molding, although any of the methods described herein may be used. Further, for the example presented in Table 1, the passage of the soft tip and the passage of the cannula are aligned and are substantially the same in shape and size.

The data are based upon a pressure differential across the cannula (and soft tip where applicable) of 66 mm of Hg. The flow rates indicated are measurements resulting from this pressure differential.

TABLE 1 Backflush Passive Flow Characteristics for Blunt and Soft Tip Cannulas Blunt Tip Soft Tip Percentage (%) of flow through Soft Gauge (cm³/min.) (cm³/min.) Tip vs. Blunt Tip 20* 14.0 10.2 72.9 23* 9.5 6.6 69.5 25* 6.0 3.9 65.0 27* 3.4 1.5 44.1 27** 3.6 3.1 86.1 *Soft tip received within passage of cannula **Soft tip formed by insert molding according to the present disclosure

Referring to the 27* gauge cannula, the flow rate through the cannula having the soft tip is approximately 44% of the flow through the corresponding blunt tip cannula. That is, the soft tip cannula of the 27* gauge variety is approximately 56% less than the flow rate through the blunt tip variety. Conversely, the soft tip cannula of the 27** gauge variety has approximately 86% of flow rate of the blunt tip variety. That is, the cannula with the soft tip has only a 14% reduction in flow rate compared to the blunt tip. Further, the 3.1 cc/min. flow rate of the 27** gauge soft tip cannula is approximately 107% of the 1.5 cc/min. flow rate of the 27* gauge soft tip cannula. FIG. 10 shows the data presented in Table 1 in a graphical representation. In FIG. 10, the data identified by “27 Ga Continuous” corresponds to the 27** gauge data presented in Table 1.

In some implementations, the elongated portion may be any gauge cannula. For example, in some instances, the elongated portion may have a gauge size within the range of 7 to 32. Thus, in some instances, the elongated portion may have a lumen with an inner diameter between 0.150 in (3.810 mm) to 0.00325 in (0.0826 mm). In some implementations, the elongated portion may have a gauge size of 25 gauge or less. Particularly, in some instances, the elongated portion may have a gauge size within the range of 25 to 32 gauge.

It should be understood that, although many aspects have been described herein, some implementations may include all of the features, others may include some features while including other, different features, and in still other instances, other implementations may omit some features while including others. That is, various implementations may include one, some, or all of the features described herein. It will be understood by those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the disclosure, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described examples. Accordingly, various features and characteristics as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated example implementations, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present disclosure as set forth in the appended claims. 

What is claimed is:
 1. A method of forming a medical instrument comprising: preparing a distal end of an elongated portion for attachment of a soft tip comprising laser cutting, water jet cutting, milling, drilling, chemical etching, electrolytic etching, electron discharge machining, or a combination thereof; attaching a tip to the distal end of the elongated portion comprising molding; injection molding, insert molding, extrusion, adhering, or a combination thereof
 2. The method of claim 1, wherein the elongated portion comprises: a distal end; and a first passage extending through the elongated portion, wherein the tip comprises a second passage substantially equivalent in size to the first passage, wherein the tip is coupled to the distal end of the elongated portion at an engagement site, and wherein the engagement site has a surface area greater than a cross-sectional area of the instrument body.
 3. The method of claim 2, wherein the engagement site comprises a tongue and groove connection.
 4. The method of claim 3, wherein the tongue and groove connection comprises: at least one tongue formed on one of the elongated portion or the tip; at least one groove formed on the other of the elongated portion or the tip, wherein the at least one tongue and the at least one groove are interlocked with each other.
 5. The method of claim 2, wherein the engagement site comprises an enhanced surface to which the tip is molded.
 6. The method of claim 2, wherein the second passage is tapered.
 7. The method of claim 1, wherein the elongated portion comprises a needle or cannula.
 8. The method of claim 7, wherein the elongated portion has a gauge size of 25 or less.
 9. The method of claim 1, wherein at least a portion of the tip comprises silicone, polyurethane, polyethylene, polypropylene, polystyrene, polytetrafluoroethylene, fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), polyether ether ketone (PEEK), polyetherimide (PEI), polyamide imide (PAI), thermoplastic polyimides (TPI), polybenzimidazol (PBI), rubber, latex, combinations thereof, or other polymer or plastic compounds. 